{"id":13215,"date":"2019-09-20T10:03:40","date_gmt":"2019-09-20T14:03:40","guid":{"rendered":"https:\/\/roofingmagazine.com\/?p=13215"},"modified":"2019-10-30T09:56:41","modified_gmt":"2019-10-30T13:56:41","slug":"cornell-university-restoration-project-puts-team-to-the-test","status":"publish","type":"post","link":"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/","title":{"rendered":"Cornell University Restoration Project Puts Team to the Test"},"content":{"rendered":"\n
\"\"
Photo: Cornell University<\/figcaption><\/figure><\/div>\n\n\n\n

Originally built in 1868, Morrill Hall was the first newly constructed building on Cornell University\u2019s<\/a> campus in Ithaca, New York. It is one of three structures built using Ithaca bluestone that are collectively known as \u201cStone Row.\u201d<\/p>\n\n\n\n

Buildings don\u2019t\nlast forever. Some need to be renovated every 150 years or so, and Morrill Hall\nis no exception. This year Cornell University and Charles F. Evans Company,\nInc. completed an ambitious and extensive structural renovation project\ndesigned to restore the building to its former glory. <\/p>\n\n\n\n

The scope of work included\nreplacing the entire roof system at Morrill Hall, including the slate on the mansards\nand the standing seam metal on the main roof \u2014 a total of 3,780 square feet in\nall. Additional work included rebuilding and waterproofing the built-in\ngutters, replacing all 27 fourth-floor windows, repairing the ornamental wood\ncornice, and repointing the stone chimneys.<\/p>\n\n\n\n

\"\"
Morrill Hall was originally built in 1868. It was constructed from Ithaca bluestone. Photo: Charles F. Evans Company, Inc.<\/figcaption><\/figure><\/div>\n\n\n\n

The installation challenges were daunting, but so were the environmental concerns posed by the existing materials, which included asbestos and lead. It would take a talented team of design and construction professionals to make it happen. Companies formulating and executing the overall plan included architect Bell & Spina<\/a>, the construction team at Cornell University, and Charles F. Evans Company, Inc., which served as both the construction manager and roof system installer on this project. <\/p>\n\n\n\n

Members of parent\ncompany Evans Roofing Company Inc. and Charles F. Evans Company, Inc., who\nshared their insights on the project with Roofing<\/em>\nmagazine included Bob Pringle, vice president at Evans Roofing Company; Don\nSewalt, construction manager at Charles F. Evans Company; and Dan Nowak, corporate\nrisk manager at Evans Roofing Company. They cited the teamwork of everyone\ninvolved on the project as the key to overcoming its many challenges. \u201cThe\nsuccess story for this project was the working partnership we developed with all\nof the stakeholders,\u201d says Pringle.<\/p>\n\n\n\n

Environmental Concerns<\/strong><\/h4>\n\n\n\n

Before restoration\nwork could begin, known hazardous materials had to be removed. \u201cThere were\nmultiple environmental issues on this job, including asbestos, lead in the\nmetal and lead in the piping of the window glazing,\u201d notes Pringle. \u201cWe had to\nabate all of these areas prior to even tearing off the existing roof.\u201d<\/p>\n\n\n\n

\"\"
Ventilators were custom fabricated in Charles F. Evans Company, Inc.\u2019s sheet metal shop. Crews also installed permanent anchor points pre-engineered by Thaler Industries. Photo: Charles F. Evans Company, Inc.<\/figcaption><\/figure><\/div>\n\n\n\n

The company is\nlicensed and all personnel certified in both asbestos and lead abatement for\nthe construction industry. \u201cWe are licensed and certified in New York State to\nremove roofing, which is a significant benefit for our client in reducing\ncosts,\u201d Pringle says. \u201cNew York State has very stringent standards, which\nCharles F. Evans Company, Inc. goes above and beyond for their abatement\npractices.\u201d<\/p>\n\n\n\n

Care had to be\ntaken to ensure no faculty members, students or pedestrians inside or outside\nthe building would be exposed to contaminants or debris. Proper barricades and\nsignage were used to keep everyone away from the abatement areas during the\nremoval process. <\/p>\n\n\n\n

Due to the lead\ntime required for the abatement process and the windows, work began at the\nmansards. W.L. Kline was called in as a subcontractor to rebuild the cornice, remove\nand install the windows, and handle finished carpentry on the window frames.<\/p>\n\n\n\n

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The radiused roofs over the dormer windows were field fabricated. Photo: Charles F. Evans Company, Inc.<\/figcaption><\/figure><\/div>\n\n\n\n

As the slate was being removed, roofing crews began the process of removing and rebuilding the gutters. The existing gutter system had to be removed according to the abatement standards, as it was constructed of lead-coated copper and lined with a built-up system containing asbestos in the felt. After the original structural sills were replaced, the gutter was rebuilt and topped with Kemperol 2K PUR, a membrane-reinforced, liquid-applied waterproofing system manufactured by Kemper System<\/a>. <\/p>\n\n\n\n

The next step was replacing the curved dormer roofs. \u201cAs we installed plywood on the mansard, we also removed the radiused roofs over the dormer windows,\u201d says Sewalt. \u201cWe were field fabricating all of the sheet metal, which was a Freedom Gray flat seam. Everything was covered with ice and water shield. We used Polystick MTS, and then covered that with 30-pound felt from CertainTeed<\/a> before all the radiused roofs were hand soldered in place.\u201d <\/p>\n\n\n\n

Installing the Roof Systems<\/strong><\/h4>\n\n\n\n

As crews continued on the mansard sections, others began to tackle the main roof. On the mansard, crews installed North Country Unfading Black roofing slate supplied by New England Slate Company<\/a>. The slate was custom cut to a hexagon shape to match the originals. The slates were all hand nailed in place. Some of the slate had to be hand cut to fit precisely around the curved dormer roofs. Making sure the courses lined up perfectly where they met up at the top of the dormers was critical. \u201cIt was meticulous work,\u201d Sewalt says. <\/p>\n\n\n\n

\"\"
The building was fully scaffolded at the eaves. All scaffolded surfaces are fully planked and included a guardrail system and debris netting. Photo: Charles F. Evans Company, Inc.<\/figcaption><\/figure><\/div>\n\n\n\n

Where the mansard\nroof meets the upper roof, attention to detail was crucial. \u201cWe shop fabricated\nour own cornice metal and counter-flashed the top course of slate,\u201d says\nSewalt. \u201cWe tied in to the eave of the Terne-coated stainless on the upper\nroof.\u201d <\/p>\n\n\n\n

Metal for the upper roof was purchased from Roofinox <\/a>in coils, and the stainless-steel panels were fabricated in Charles F. Evans Company\u2019s<\/a> sheet metal shop. After the old roof was removed, new three-quarter-inch plywood was installed over the top of the existing random rough-cut deck boards. Crews then applied Polystick MTS self-adhered underlayment and rosin paper before installing the double-lock metal panels. <\/p>\n\n\n\n

The original Ithaca bluestone chimneys were repointed by R.E. Kelley<\/a>, the masonry restoration subcontractor, and new shop-fabricated step flashings were installed. Charles F. Evans Company also fabricated the large ventilators. \u201cThe louvered ventilators were very detailed,\u201d Sewalt points out. \u201cThey were all custom fabricated in our sheet metal shop.\u201d<\/p>\n\n\n\n

One of the last phases of the roofing portion of the project was the installation of low-slope roofs on two lower-level areas that covered mechanical rooms. \u201cWe installed a two-ply modified bitumen system by Soprema<\/a>,\u201d Sewalt says. \u201cWe used Sopralene 180 sanded as a base, and Sopralene 180 FR GR White as the cap.\u201d <\/p>\n\n\n\n

The Safety Plan<\/strong><\/h4>\n\n\n\n

The height, age\nand nature of the work posed numerous safety concerns, according to Pringle,\nbut experience on other similar projects helped the company structure a\ndetailed safety, health and environmental plan for Morrill Hall. \u201cCharles F.\nEvans Company, Inc. is a VPP Mobile Workforce STAR contractor, the only union\nroofing company in the United States to have this prestigious status,\u201d notes\nPringle. \u201cWe had to make sure all of our employees were safe, as well as\nstudents, faculty, and the members of the public.\u201d<\/p>\n\n\n\n

\"\"
The black roofing slate supplied by New England Slate Company was custom cut to a hexagon shape to match the original. Photo: Charles F. Evans Company, Inc.<\/figcaption><\/figure><\/div>\n\n\n\n

A scaffolding system\nwas central to the safety plan. \u201cWe had this one fully scaffolded,\u201d notes\nNowak. \u201cWe try to do this on all of projects if we can. We do it for safety, of\ncourse, but secondly it makes it a little bit easier for our crews. Going up a\nscaffolded stair tower sure beats a ladder any day for safety, and all\nscaffolded surfaces are fully planked with a guardrail system and debris\nnetting. This way, it protects everyone occupying it and staging our materials\nand tools are allowed with the proper load ratings. It makes it so much easier\nto look at the work right in front of them and do the work in a safe manner.\u201d<\/p>\n\n\n\n

On the upper roof,\nworkers were tied off 100 percent of the time. As part of the project, crews\nalso installed permanent anchor points pre-engineered by Thaler Industries. <\/p>\n\n\n\n

\u201cCornell has\nalways been on the forefront with safety, not only for the public, the students\nand the faculty, but their maintenance crews as well,\u201d Nowak says. \u201cWe are\nseeing a lot more permanent fall protection being installed on campus buildings,\nwhich is a great thing.\u201d <\/p>\n\n\n\n

The safety plan\nhad to also protect people entering the building, as it was in use for much of\nthe installation process. \u201cWe had to have proper barricades, signage, and of\ncourse entryway protection,\u201d Nowak says. \u201cWe basically created a tunnel system\nwith overhead protection so people could access the building.\u201d <\/p>\n\n\n\n

Landmark Renovation<\/strong><\/h4>\n\n\n\n

Roofing work began\nin June 2018 and was completed in December 2018, so inclement weather was\nanother big challenge, but the project was completed on time with zero safety\nincidents. According to Pringle, one key to meeting the deadline was the\ncompany\u2019s ability to handle the abatement work itself, which optimized\nefficiency. \u201cEverybody on that rooftop was certified for abatement, so we could\ntear and go and keep moving without calling in a subcontractor,\u201d Pringle states.\n\u201cIt\u2019s critical that we can do this work ourselves.\u201d<\/p>\n\n\n\n

Pringle and Sewalt\ncommended everyone who worked on the project, including Jim Wilson, roofing\nsuperintendent; Brian Babcock, sheet metal superintendent; Brett Sewalt, slate\nforeman; and Brent Spencer, sheet metal foreman. The roofing crew included\nBrian Sewalt, Nate Uram, Cal Uram, and Bill Jordan. The sheet metal crew\nincluded Sam Morich, Neal Brown, Matt Denson, Bob Corwin, Tony Hoskins, and\nJeff Worsfol. <\/p>\n\n\n\n

To rebuild the historic landmark with the products of today, bring it up to code, and maintain the original look, is a tremendous accomplishment. \u201cThis was a collaborative effort between Charles F. Evans Company, Inc., Cornell University, and Bell & Spina,\u201d Pringle says. \u201cWhat we leave behind is our craftsmanship. Our client, Cornell University, once again depended on us to deliver another landmark renovation for them. Morrill Hall will continue to dominate \u2018Stone Row,\u2019 offering students and faculty a place to learn for years to come.\u201d<\/p>\n\n\n\n

TEAM<\/strong><\/h4>\n\n\n\n

Owner\/Representative: <\/strong>Cornell University (Patrick Conrad), Ithaca, New York, www.cornell.edu<\/a><\/p>\n\n\n\n

Architect:<\/strong> Bell & Spina, Syracuse, New York, www.bellandspina.com<\/a><\/p>\n\n\n\n

Construction Manager and Roofing Contractor:<\/strong> Charles F. Evans Company, Inc., Elmira, New York, www.evansroofingcompany.com<\/a><\/p>\n\n\n\n

Window Contractor:<\/strong> W.L. Kline Inc., Binghamton, New York<\/p>\n\n\n\n

Masonry Contractor: <\/strong>R.E. Kelley, Bowmansville, New York, www.rekelley.com<\/a><\/p>\n\n\n\n

MATERIALS<\/strong><\/h4>\n\n\n\n

Slate:<\/strong> North Country Unfading Black Roofing Slate, New England Slate Company, www.newenglandslate.com<\/a><\/p>\n\n\n\n

Metal Roof Panels:<\/strong> Terne-Coated Stainless Steel, Roofinox, www.roofinox.com<\/a><\/p>\n\n\n\n

Underlayment:<\/strong> Polystick MTS, Polyglass U.S.A., Inc., https:\/\/polyglass.us<\/a><\/p>\n\n\n\n

Felt:<\/strong> Roofers\u2019 Select 30-pound Felt, CertainTeed, www.certainteed.com<\/a><\/p>\n\n\n\n

Flat-Seam Dormer Roofs:<\/strong> Revere Freedom Grey copper, Revere Copper, www.reverecopper.com<\/a><\/p>\n\n\n\n

Modified Bitumen Roof:<\/strong> Sopralene 180 and Sopralene 180 FR GR, Soprema, www.soprema.com<\/a><\/p>\n\n\n\n

Gutter Lining:<\/strong> Kemperol 2K PUR, Kemper System, www.kemper-system.com<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

Photo: Cornell University Originally built in 1868, Morrill Hall was the first newly constructed building on Cornell University\u2019s campus in Ithaca, New York. It is…<\/p>\n","protected":false},"author":125,"featured_media":13217,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":true,"jetpack_social_options":{"image_generator_settings":{"template":"highway","enabled":false}}},"categories":[35,4200,34],"tags":[8970,7379,8968,1353,8969,8973,288,8972,8971],"jetpack_publicize_connections":[],"yoast_head":"\nCornell University Restoration Project Puts Team to the Test - Roofing<\/title>\n<meta name=\"description\" content=\"Originally built in 1868, Morrill Hall was the first newly constructed building on Cornell University\u2019s campus in Ithaca, New York.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Cornell University Restoration Project Puts Team to the Test - Roofing\" \/>\n<meta property=\"og:description\" content=\"Originally built in 1868, Morrill Hall was the first newly constructed building on Cornell University\u2019s campus in Ithaca, New York.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/\" \/>\n<meta property=\"og:site_name\" content=\"Roofing\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/RoofingMagazine\/\" \/>\n<meta property=\"article:published_time\" content=\"2019-09-20T14:03:40+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2019-10-30T13:56:41+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/roofingmagazine.com\/wp-content\/uploads\/2019\/09\/cropped-Screen-Shot-2019-09-20-at-10.17.15-AM-1024x575.png\" \/>\n\t<meta property=\"og:image:width\" content=\"1024\" \/>\n\t<meta property=\"og:image:height\" content=\"575\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/png\" \/>\n<meta name=\"author\" content=\"Chris King\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:creator\" content=\"@roofingmag\" \/>\n<meta name=\"twitter:site\" content=\"@roofingmag\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Chris King\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"9 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/#article\",\"isPartOf\":{\"@id\":\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/\"},\"author\":{\"name\":\"Chris King\",\"@id\":\"https:\/\/roofingmagazine.com\/#\/schema\/person\/8bb37637eb1320744997c728836a6974\"},\"headline\":\"Cornell University Restoration Project Puts Team to the Test\",\"datePublished\":\"2019-09-20T14:03:40+00:00\",\"dateModified\":\"2019-10-30T13:56:41+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/\"},\"wordCount\":1801,\"commentCount\":0,\"publisher\":{\"@id\":\"https:\/\/roofingmagazine.com\/#organization\"},\"image\":{\"@id\":\"https:\/\/roofingmagazine.com\/cornell-university-restoration-project-puts-team-to-the-test\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/roofingmagazine.com\/wp-content\/uploads\/2019\/09\/cropped-Screen-Shot-2019-09-20-at-10.17.15-AM.png\",\"keywords\":[\"Bell & Spina\",\"Charles F. 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